| —- 4 Ninja ZX-7RR Kawasaki Ninja ZX-7R Motorcycle Service ManualLIST OF AB3REVIATIONS A ampere(s) ib ] pound(s) ABOC after bottom dead center m | meter(s) AG. altemating current min | minute(s) TDC | after top dead center N | newton(s) BBDC | before bottom dead center Pa | pascal(s) BoC bottom dead center PS horsepower BTOC | before top dead center psi pound(s) per square inch rc degree(s) Celcius r revolution oc direct current rpm revolution(s) per minute F fared(s) TDC | top dead center F degree(s) Fahrenheit TR total indicator reading ft foot, feet v volR(s) 9 ‘grarn(s) w watt(s) A hour(s) Q chin(s) L liter(s) Read OWNER’S MANUAL before operating.Quick Reference Guide = =F General Information ——— ooo Fuel System LI Cooling System a 3 I Engine Top End 4 I | Clutch _ 5 o Engine Lubrication System Engine Removal/Installation I ~ | each Anite 5 | Crankshaft/Transmission 8 I Wheels/Tires [9 I Brakes Suspension Frame [Etectricalsystem 15] This quick raference guide will assist you in locating 2 desired topic ur procedure. ‘@Bend the pages back to match the black tab Of the desired chapter number withthe black tab on the edge at each table of coments, page. Refer 10 the sectional table of contents for the exact pages to locate the specific topic required,rman fo aT ious Te ante be ts ct, Set tel apases te ecce: eetge att op vain a! aifieege et BSS 1 see TET Ay °ee bs SN EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board. Additionally Kawasaki has incorporated an evaporative emission control system (3) in compliance with applicable regulations of the California Air Resources Board on vehicles sold in California only. 4. Crankcase Emission Control System irene cece nce cae ita d “This system eliminates the release of crankcase vapors into the atmosphere. Instead, the 23! ‘vapors are routed through an oil separater to the intake side of the engine. While the engine 35> js operating, the vapors are drawn into combustion chamber, where they are burned long Se with the fuel and air supplied by the carburetion system. ca 2. Exhaust Emission Control System & ‘This system reduces the amount of pollants discharged into the atmosphere by the exhaust 35° of this motorcycle. The fuel and ignition systems of this motorcycle have been carefully $22 designed and constructed 10 ensure an eficient engine with low exhaust pollutant levels. 33 ‘3, Evaporative Emission Control System S Vawurs caused by fuel evaporation in the fuol cyctem are not vented inta the atmasnhar — $25 se Instead. fuel vaDors are routed into the running engine to be bumed, or stored in a canister 32 e when the engine is stopped. Liquid fuel is caught by a vapor separator and returned tothe 35 FE fuel rank a Se The Clean Air Act, which is the Federal law covering motor vehicle pollution, contains what is {33 223 commonly referred to as the Act's “tampering provisions.” aS "Sec. 203(a) The following acts and the causing thereof are prohibited. (3)(A) for any person to remave or render inoperative any device or element of design installed ‘on of in a motor vehicle or motor vehicle engine in compliance with regulations under this title prior to its sale and delivey to the ultimate purchaser, or for any manufacturer or dealer knowingly to remove o1 render inoperative any such device or element of design after such sale and delivery to the ultimate purchaser. (3)(B) for any person engaged in the business of repairing, servicing, selling, leasing, or trading motor vehicles or motor vehicle engines, or who operates a fleet of motor vehicles knowingly to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title following its sale and delivery to the ultimate purchaser.” EN 7d 7a bad Re (Continued on next page.NOTE ERE © The phrase “remove or render inoperative any device or element of design” has been generally interpreted as follows: 1. Tampering does not include the temporary removal or rendering inoperative of devices or elements of design in order to perform maintenance. 2, Tampering could include: 2. Maladjustment of vehicle components such that the emission standards are exceeded. b. Use of replacement parts or accessories which adversely affect the performance or durability of the motorcycle. ¢. Addition of components or accessories that result in the vehicle exceeding the standards. d. Permanently removing, disconnecting, or rendering inoperative any component or element of design of the emission contro! systems. TY cst uh et WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW, THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING $10,000 PER VIOLATION. SSE 2 brvearnerorancenenereneensensye PASTS aS ANE iS SEEDER sone TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise contol prior 10 its sale or delivery to the ultimate purchaser or while itis in use, or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. ‘Among those acts presumed to constitute tampering are the acts listed below: ‘@ Replacement of the original exhaust system or muffler with a component not in compliance with Federal regulations. @ Removal of the muffier(s) or any internal portion of the muttler(s) @ Removal of the air box or air box cover. © Modifications to the muffier(s) or air intake system by cutting, drilling, or other means if such modifications result in increased noise levels. SESE Daa hahastassussaasorsat SSAC GE Pd zm a ene eS — DEEN EAE PERERR FRGRForeword This manual is designed primary for use by ‘rained mechanics in a properly equipped shop However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the ‘proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satistactorily. Whenever the owner has insufficient experience or doubts his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics. In order to perform the work efficiently and to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures before starting work, and then do the work carefully in a clean area. Whenever special tools or equipment are specified, do not use makeshift tools or equipment. Precision measurements can only be made if the proper instruments are used, and the use of substi tute tools may adversely affect safe operation. Far the duration of the warranty period. we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual, Any owner maintenance or repair procedure not performed in accordance with this ‘manual may void the warranty. To get the longest life out of your motorcycle: Follow the Periodic Maintenance Chart in the ‘Service Manual. @Be alert for problems and non-scheduled mainte: nance. @Use proper tools and genuine Kawasaki Motorcy: cle pans. Special tools, gauges, and testers that are necessary when servicing Kawasaki motorcy: cles are introduced by the Special Tool Manu Genuine parts provided as spare parts are listed the Parts Catalog, @Follow the procedures in this manual carefully. Don't take shortcuts. Remember to keep complete records of mainte- nance and repair with dates and any new parts installed, How to Use This Manual In preparing this manual, we divided the product into its major systems. These systems became the manual's chapters. All information for a particular system from adjustment through disassembly and inspection is located in a single chapter. The Quick Reference Guide shows you all of the product's system and assists in locating their chapters, Each chapter in tum has its own compre- hensive Table of Contents. ‘The Periodic Maintenance Chart is located in the General Information chapter. The chart gives a time schedule for required maintenance operations. H you want spark plug information. for example, {go to the Periodic Maintenance Chart first. The chart tells you how frequently to clean and gap the plug. Next, use the Quick Reference Guide to locate the Electrical System chapter. Then, use the Table of Contents on the first page of the chapter to find the Spark Plug saatinn, Whenever you see these WARNING and CAUTION symbols, heed their instructions! Always follow safe operating and maintenance practices. AAWARNING This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in personal injury, oF loss of CAUTION This caution symbol identifies special instructions or procedures which, if not strictly observed. could result in damage to or destruction of equipment.This manual contains four more symbols (in addition to WARNING and CAUTION) which will help you distinguish different types of information. NOTE ©This note symbol indicates points of partic- ular interest for more efficient and convenient operation. @ indicates a procedural step or work to be done, Clndicates a procedural sub-step or how to do the work of the procedural step it follows. It also precedes the text of a NOTE. indicates a conditional step or what action to take based on the results of the test or inspection in the procedural step or sub-step it follows. In most chapters an exploded view illustration of the system components follows the Table of Contents. In these illustrations you will find the instructions indicating which parts require specified tightening torque, oil, grease or a locking agent during assembly.GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing =t22) Model Identification 4-4 General Specifications 4-8 Periodic Maintenance Chart .. A-A2 Technical Information ~ Maintenance Free Battery 4.13 Technical information - Fiat CR Slide Carburetor. 447 Technical Information ~ Side Camshaft Chain... “119 Technical Information - Engine Lubrication System on... seo =20 Technical Information - Connecting Rod per End Nut peta, acs Technical Information — Swingant enon 24-24 Technical Information — Altemator Unit 24 ‘Torque and Locking Agent... 25 Special Tools and Sealant 1-30 Cable, Wire, and Hose Routing ee [181-2 GENERAL INFORMATION Before Servicing Before starting to service a motorcycle, careful reading of the applicable section is recommended to eliminate unnecessary work. Photographs, diagrams, notes, cautions, warnings, and detailed descriptions have been included wherever necessary. Nevertheless, even a detailed account has limitations, a certain amount of basic knowledge is also required for successful work. Especially note the following: 1) Dit Before removal and disassembly, clean the motorcycle. Any dirt entering the engine or other parts will work as an abrasive and shorten the life of the motorcycle. For the same reason, before installing a new par, clean off any dust or metal filings. (2) Battery Ground Remove the ground (-) lead from the battery before performing any disassembly operations on the motorcycle. This prevents: (@) the possibility of accidentally turning the engine over while partially disessembled. (©) sparks at electrical connections which will occur when they are disconnected. (©) damage to electrical parts. (3) Tightening Sequence Generally, when installing a part with several bolts, nuts, or sorews, start them all in their holes and tighten them to a snug fit. Then tighten them eveniy in a cross pattern. This is to avoid distortion of the part and/or causing gas or oil leakage. Conversely when loosening the bolts, nuts, or screws, first loosen all of them by about ¢ quarter turn and then remove them. Where there is a tightening sequence indication in this Service Manual, the bolts, nuts, or screws must be tightened in the order and method indicated, (4) Torque ‘When torque values are given in this Service Manual, use them. Either too litle or too much torque may lead to serious damage. Use a good quality, reliable torque wrench. (5) Force ‘Common sense should dictate how much force is necessary in assembly and disassembly. If a part seems especially difficult to remove or install, stop and examine what may be causing the problem. Whenever tapping is necessary, tap lightly using a wooden cr plastic-faced mallet. Use an impact driver for screws (particularly for the removal of screws held by a locking agent) in order to avoid damaging the screw heads. (6) Edges Watch for sharp edges, especially during major engine disassembly and assembly. Protect your hands with gloves or a piece of thick cloth when lifting the engine or turning it over. (7) High-Fiash Point Solvent ‘A high-flash point solvent is recommended to reduce fire danger. A commercial solvent commonly available in North America is Stoddard solvent (gereric name). Always follow manufacturer and container directions regarding the use of any solvent. (8) Gasket, O-Ring Do not reuse @ gasket or O-ring once it has besn in service. The mating surfaces around the gasket should be free of foreign matter and perfectly smooth to avoid oil or compression leaks. (8) Liquid Gasket, Non-Permanent Locking Agent Follow manufacturer's directions for cleaning and preparing surfaces where these compounds will be Used. Apply sparingly. Excessive amounts may block engine oil passages and cause serious damage. An example of a non-permanent locking agent commonly available in North America is Loctite Lock’n Seal (Blue) (10) Press A part installed using a press or driver, such as a wheel bearing, should first be coated with oillon its outer or inner circumference so that it will go into place smoothly. (11) Ball Bearing and Needle Bearing Do not remove any ball or needle bearings that are pressed in unless it is necessary. If they are removed, replace them with new ones. When installing a bearing, press it in with the rarked side facing out using a suitable driver until itis bottomed. Bearings should be pressed into place by pushing evenly the bearing race which is affected by friction.GENERAL INFORMATION 1- (12) Oil Seat and Grease Seal Replace any oil or grease seals that were removed with new ones, as removal generally damages seals. When pressing in a seal which has manufacturer's marks, press it in with the marks facing out. Seals should be pressed into place using a suitable driver, which contacts evenly with the side of seal, until the face of the seal is even with the end of the hole, (13) Seal Guide ‘A seal guide is required for certain oil or grease seals during installation to avoid damage to the seal lips. Before a shaft passes through a seal, apply a litle high temperature grease on the lips to reduce rubber to metal friction. (14) Cicclip, Retaining Ring Replace any circlips and retaining rings that were removed with new ones, as removal weakens and deforms them. When installing circlips and revaining rings, take care to compress or expand them only ‘enough to install then and no more. (18) Cotter Pin Replace any cotter pins that were removed with new ones, as removal deforms and breaks them. (18) Lubrication Engine wear is generally at its maximum while the engine is warming up and before all the rubbing surfaces have an adequate lubricative film. During assembly, oil or grease (whichever is more suitable) should be applied to any rubbing surface which has lost its lubricative film. Old grease and diny oil should be cleaned off. Deteriorated grease has lost its ubricative quality and may contain abrasive foreign particles. Don’t use just any oll or grease. Some oils and greases in particular should be used only in certain applications and may be harmful if used in an application for which they are not intended. This manual makes reference to molybdenum disulfide grease (MoS: ) in the assembly of certain engine and chassis. parts, Always check manufacturer recommendations before using such special lubricants. (17) Electrical Wires ‘All the electrical wires are cithor single colar or two eolor and, with only a fow oxcoptione, muct be ‘connected to wires of the same color, On any of the two-color wires there is 2 greater amount of one color and a lesser amount of a second color, so a two-color wire is identified by first the primary color and then the secondary color. For example, a yellow wire with thin red stripes is referred to as a “yellow/red” wire: it would be a “red/yellow" wire if the colors were reversed to make red the main color. Wire (cross-section) Name of Wire Color Red Wire Stands Yellow/Red Yellow Red (18) Replacement Parts ‘When there is a replacement instruction, replece these parts with new ones every time they are removed. These replacement parts will be damaged or los2 their original function once removed. (19) Inspection When parts have been disassembled, visually inspect these parts for the following conditions or other damage. f there is any doubt as to the conditicn of them, replace them with new ones. Abrasion Crack Hardening Warp Bent Dent Serateh Wear Color change Deterioration Seizure (20) Specifications ‘Specification terms are defined as follows: "Standards" show dimensions or performances which brand-new parts or systems have. "Service Limits’ indicate the usable limits. if the measurement shows excessive wear or deteriorated performance, replace the damaged parts.1-4 GENERAL INFORMATION Model Identification ‘ZX750-N1 (US and Canada Models) Loft Side View: ZX760-N1 (US and Canada Models) Right Side Visw:GENERAL INFORMATION 1-5 ZX750-N1 (Europe Modal) Left Side View: ZX750-N1 (Europe Model) Right Side View:1-6 GENERAL INFORMATION 2X750-P1 (US and Canada Models) Loft Side View: ZX70-P1 (US und Canada Models) Right Side View:GENERAL INFORMATION 1-7 2X750-P1 (Europe Model) Left Side View:1-8 GENERAL INFORMATION General Specifications Item | De7s0-n1, 2 Dimensions: Overall length 2.080 mm, (FG) 2 190 mm Overall width 740 mm Overall height 1130mm Wheelbase 1.420 mm Road clearance 105 mm Seat height 790 mm Dry weight 200 kg. (CA) 201 kg Curb weight: Front 117 kg, (CA) 117.5 kg Rear 112kg, (CA) 1125 kg Fuel tank capacity 180 Performance: Minimum turning radius 34m Engine: Type 4-str0ke, DOHC, 4-cylinder Cooling system Liquid-cooled Bore and stroke 73.0 x 44.7 mm Displacement 748 mL Compression ratio 11.5, (FR) 108 Maximum horsepower 90 KW (122 PS) @12 000 r/min (rom). (FR) UTAC’s norm 75.1 kW (102 PS) @11 500 r/min (rpm), (AR) 72 kW (98 PS) @12 000 r/min (rpm). (FG) DIN 72kW (98 PS) @12 000 r/min (rpm), (US) — Maximum torque 78 N-m (8.0 kg-m, 57.9 ft-lb) @8 300 s/n (span (AR) 73 N-m (7.4 kg-m, 83.5 ft-lb) @7 000 r/min (rom). (FG) DIN 73 N-m (7.4 kg-m, 63.5 ft-lb) @7 000 «/min (7pm), (FR, US) — Carburetion system | Carburetors, Keihin FVK-D41 x 4 Starting system Electric starter Ignition system Battery and coil (transistoized) Timing advance Electronically advanced (digital) Ignition timing From 10° BTDC @1 100 r/min (rpm) to 45° BTDC @5 000 r/min (rpm) (AR, CA, FG) From 5° BTDC @t 300 r/min (rpm) to 40° BTDC @3 000 r/min (rpm) Spark plug NGK CR9E o ND U27ESR-N Cylinder numbering method Left to right, 1-2-3-4 Firing order 1-2-4-3 Valve timing: Inlet Open 44° (BTDC), (FR) 27° (BTDC) Close 64° (ABDC), (FR) 57" (ABDC) Duration 288", (FR) 264° Exhaust Open 54° (BBDC), (FR) 57° (BBDC) Close 34° (ATDC), (FR) 27° (ATDC) Duration 268", (FR) 264° Lubrication system Forced lubrication (wet sump with cooler)GENERAL INFORMATION 1-9 fem ZX750-NI, N2 Engine oil: Grade SE. SF or SG class Viscosity ‘SAE1OW-40, 10W-50, 20W-40, or 20W-50 Capacity 36L Drive Train: Primary reduction system: Type Gear Reduction ratio | 1.754 (93/53) Clutch type Wet multi disc Transmission: Type 6-speed, constant mesh, return shift Gear ratios: Ist 2.375 (38/16) 2nd 1.894 (36/19) 3rd 1.619 (34/21) ath 1.409 (31/22) 5th 1.291 (31/24) 6th 1.200 (30/28) Final drive system: | Type Chain drive Reduction ratio Overall drive ratio 2.625 (42/16) 5.527 @lop gear Frame: Type Press, diamond Caster (rake angle) 2S Trail 99 140 Front tira: Type Tubeless Size 120/70 2817 Rear tire: Type Tubsless Size 190/50 2R17 Front suspension: Type Telescope fork Wheel travel 120 mm Rear suspension: Type ‘Swing arm (uni-trak) Whee! travel 130 mm Brake type: Front Dual discs Rear Single disc Electrical Equipment: Batlery 12V8 Ah Headlight Type Semi-sesled beam Bulb (Quarz-hslogen Left 12.V 55 W, Right 12 V 55 W (US, CN, UK) 12 V 45/45 Wx 2 Tail/orake light 12. 5/21 Wx 2, (US, CN) 12 V 8/27W x2 Altemator: Type Ihree-phase AC Rated output 30.7 A/ 14 V @6 000 r/min (rpm) ‘Specifications are subject to change without notice, and may not apply to every country. (AR) : Austria Model (CA) : California Model (CN) : Canada Model (FG) ; Germany Model (FR) : France Model U.K. Model U.S. Model (UK) (us)1-10 GENERAL INFORMATION lem Dimensions: 2X750-P1, P2, P3, Pa Overall length 2.090 mm, (FG, GR, NR, SD, ST) 2190 mm Overall width 740 mm Overall height 1130mm Wheelbase 1.435 mm Road clearance 105 mm Seat height 790 mm Dry weight 203 kg, (CA) 204 kg Curb weight: Front 117 kg, (CA) 117.5 ka Rear 115 kg, (CA) 1155 ka Fuel tank capacity 1801 Performance: Minimum turning radius 34m Engine: Type 4-stroke, DOHC, 4-cylinder Cooling system Bore and stroke Displacement Compression ratio Maximum horsepower Maximum torque Carburetion system Starting system Ignition system Timing advance Ignition timing ‘Spark plug Cylinder numbering method Firing orcer Valve timing: Inlet Open Close Duration Exhaust Open Close Duration Lubrication system Engine oi Grade Viscosity Capacity Liquid-cooled 73.0 x 44.7 mm 748 mL, 11.5, (FR) 10.8 90 KW (122 PS) @11 200 r/min (rpm). (AR) P1 - P3: 72 kW (98 PS) @11 500 r/min (rpm), (FG) Pt — P3: DIN 72 kW (98 PS) @11 500 r/min (pm) (FR) UTAC’s norm 75.1 KW @11 000 r/min (epm) (SD) 81 kW (83 PS) @9 500 r/min (rpm) (ST) 39 KW (53 PS) @7 800 r/min (rpm). (us) - 78 N-n (80 kg-m, 57.9 ft-lb) @9 300 r/min (rom). (AR) P1 = P3: 74 N-m (7.6 kg-m, 54.2 ft-lb) @6 800 r/min (rpm), (FG) P1 - P3: DIN 74 N-m (7.5 kg-m, 54.2 ft-lb) @6 800 r/min (rpm) (SD) 70 N-m (7.1 kg-m, 51,4 ft-ib) @6 500 r/min (rpm), (ST) 56 Nem (5,7 kg-m, 12 ftela) @5 000 r/min (rpm) (FR. US) ~ KEIHIN CVK-D38 x 4 Elec staner Battery anc coil (ansistorized) Electronica ly advanced (digital) From 10° BTDC @1 100 ¢/min (rpm) to 45° BTDC 25 000 r/min (*p™), (AR. CA, FG, ST) From 5° BTOC @1 300 r/min (rpm) to | 40° BTDC @5 000 r/min (rpm) NGK CR9E or ND U27ESR-N Left to right, 1-2-3-4 | 4.2.4.3 | 44* (BTOC), (FR) 27° (BTDC) | 6a" (ABDC), (FR) 67° (ABDC) | 238". (FR) 26a" 84" (BBOC), (FR) 57° (BBDC) | 34 (ATDO, (FR) 27° (ATDC) 268", (FR) 264° Forced lubication (wet sump with cooler) SE, SF or $6 class SAETOW-40, 10W-80, 20W-40, or 201-50 36LGENERAL INFORMATION 1-11 Item | 2x750-P1. P2, P3, Pa Drive Train: | Primary reduction system: Type Gear Reduction retio | 1.764 (99/62) Clutch type Wet multi disc Transmission | Type | 6-speed, constant mesh, return shift Geer ravos: tat 2.857 (40/14) 2nd | 2000 36/19) 3rd 1619 (34/21) ath 1.381 (32/23) 5th | 1.222 (33/27) ah | 1.103 (22/28) Final drive system: Type | Chain are Reduction ratio. | 2.687 (43/16) Overall drive ratio | 5.203 @Top gear Frame: Type Press, dimond Caster (rake angle) 25 Tail 99 mm Front tie: Type Tubeless Size 120/70 2817 Rear tire: Type Tubeless Sie TyuyE any Front auspension: Typ Telescope fork Wheel travel 120 mm Rear suspension: Type ‘Swing arn (uni-trake) Wheel travel 430 mm Brake type! Front Dual discs Rear Single disc Electrical Equipment: Battery 1210 4h Headlight Type | Semi-sealed beam Bulb Quarz-helogen Left 12 V 85 W, Right 12 V 55 W (AS, CN, UK, US) 12 V 45/45 Wx 2 Tail/orake light 12.V 5/21 W x 2, (US, CA, CN) 12V 8/27 W x 2 Altemator: Type Three-phase AC Rated output 30.7 A / 14 V @6 000 r/min (rpm) Specifications are subject to change without notice, and may not apply to every country. (AR) = Austria Model (GR) + Greece Mode! (AS) + Australia Mode! (NR) : Norway Mods! (CA) : California Mods! (SD) : Sweden Model (CN) : Canada Mode! (ST): Switzerland Model (FG) : Germany Mode! (UX): UK Modet (FR): France Model (US) : U.S. Model1-12_ GENERAL INFORMATION Periodic Maintenance Chart ‘The scheduled maintenance must be done in accordance with this chart to keep the motoreycle in good running condition. The initial maintenance is vitally important and must not be neglected. FREQUENCY OPERATION Whichever cones first "ODOMETER READING ‘Spark plug — clean and gap t Valve clearance - check t Air Suetion valve ~ check Air cleaner element — clean t# Throttle grip play ~ check t Idle speed ~ check + Carburetor synchronization — check + Evaporative emission control system (CA) = check t Engine oil - change # Gmonths| @ Oil filter = replace Drive chain wear ~ check + # Brake pad wear - check t # Brake light switch ~ check ‘Steering - check elelele Front fork oil - change 2 years Teer shock absorber oll Ioak check t Front fork oil leak — check t Tire wear = check t ‘Swingarm pivot, uni-irak linkage — lubricate ‘General lubrication — perform Nuts, bolts, and fasteners tightness — check t Drive chain ~ lubricate # 600 km Drive chain slack — check 1 # 1000 km ‘Brake fluid level ~ check F month Clutch fluid level - check t ‘month Radiator hoses, connection — check t elelele Brake fluid ~ change 2 years Brake master cylinder cup and dust seal = replace 4 years Coolant = change Z years Caliper piston seal and dust seal - replace 4 years Steering stem bearing — lubricate 2 years Clutch fluid — change 2 years Clutch master cylinder cup and seal ~ replace 4 years Clutch slave cylinder piston seal - replace 4 years, # —: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed, or frequent starting/stopping. +: For higher odometer readings, repeat at the frequency interval established here. : Replace, add, adjust, clean, or torque if necessary. ait (CA): California Model onlyGENERAL INFORMATION 1-13 Technical Information - Maintenance Free Battery ‘A maintenance free battery is installed in this model, The maintenance free battery is @ sealed type, and so the electoivte id topping up ca erformed. ()) Construction sealing plug, Lid (P.P.) Terminal {lead-calcium alloy) Filter, Safety valve Filler plug Pole (leac-calcium alloy) Negative plate (lead and lead-calcium alloy} cavtamnere.P Special separator Positive plate (lead and lead-calcium alloy) (ll) Main Features 1) Maintenanes free... va It isnot neceseary to check the electolyte level and top-up the electro, 2) No electrolyte leakage... {As the electrolyte is retained firmly in the special separators, there is no 3) Instant activation system {ree electrolyte in the battery. chara. 4) One-push motion electrolyte fling........ It's possible to fil the electrolyte by easy one-pusn motion. 6) Safety concretion IF fie botery tera pressure ross abrrmaly Figh, Te safety valve It can be used instently alter filing only the electrolyte without intial ‘opens ‘6 release the gat inside the battery to restore the normal pressure Ghd prevent the bettery from rupturing. Alter restoring the normal presume, the safety valve closes and the battery is sealed again Rroreover, 2 ceramic filter is dispased on top of the safety valve under the lidto remove risk af ignition or explosion caused by fire from outside. No presence of free electrolyte allows the battery made lower in height, thus resulting in. enhenead volume efficiency.” Moreover, gas beng . fabsorbad inside the bettery eliminates the need for a gas exhaust tube, 7) Strong charge/cischarge characteristics... Itcan amply withstand deep charge/discharge cycles. (un Principle of Sealing Structure "hiigad- acid battery operates under the following chemeal resction: 6) Compact and high performance. el ()— Dischage (4) (-) PbO. + «(MSOs + Pb > POSOs + © 2Hx0 = PDSO (Lead peroxide) (Sulfricacid) —-(Spongylead) Charge (Lead sulfate) (water) (Load sulfate) Positive active Elecwoiye Negative active Postiveactive Electrolyte Negative active material ‘materiel materia ‘materal Normally in an ordinary lead-acid battery when it comes to an end of a charge. where the lead sulfate being 2 discharge product returns to lead peroxide and spongy lead, the ctarge current flowing therestter is usod exclusively to decompose Electtolytically weter from the electrolyte, thus resulting in generation of hydrogen gas from the negative plats and oxygen ‘Gas from the positive plata. The gates so genereted am released out of the battery, causing the amount of elactaiyte decreased to require cecasional weter replenishment "A maintenance ‘ree battery, however, is so designed that, when itis overcharged, even ifthe positive plata fully charged, the negative plote remains not fully turned to spongy lead. Therefore, even when the positive plate is overcharged generating ‘oxygen gés, the negative plate is not fully charged, hence generating no hydrogen gas. "wloreover, tha oxygen gas generated from the positive plate immediately reacts with the eherged active material on the negative plate, and returns to water, with the ultimate cesult of no water loss.1-14 GENERAL INFORMATION Pb + 1/202 + (PRO) Negative active Oxygen generated Negative active material from positive plate ‘materal (charged state) (PbO) + HeSOs + PhSOL + HO. Electrolyte Negative active Water ‘material (charged state) ‘Thus. the negative plate is made as not to get fully charged. Even if the overcharge continues, the oxygen gas generated inside the battery is absorbed by the negative plate, process called oxygen cycle, which theoretically prevents water loss, and allows the battery to be sealed. (1) Filling the Battery with Electrolyte CAUTION Do not remove the aluminum seal sheet sealing the fillar port unt Just before use. Be sure to use the dedicated electrolyte container for correct electrolyte volume. ‘@Check to see that there is no peeling, teas or holes in the sealing sheet. ‘@Place the battery on a level surface. Remove tho sealing sheet [A]. [When ramaving, ehac ta heat an air-suicking sound "Sheesh!" from filler ports [B]. NOTE A bartory whose sealing sheot hae any pooling, tears, holes, or from Which the air-sucking sound was not heard requires @ refreshing ‘charge (inital charge). (@ Teke the electrolyte container out of the vinyl bag. ‘® Detach the strip of caps [A] from the container. NOTE 000 not discard the stip of caps becouse it is used as the battery ‘plugs later (2Do nar peel back or pierce the sealed areas (8) (© Place the electrolyte container upside down with the six sealed areas in line with the six battory filler ports. ‘@Push the container down strongly enough to break the seals. Now the ‘electrolyte should start to flow into the better. NOTE (0Do not tit the container as the electrolyte tlow may be interrupted.GENERAL INFORMATION 1-15 (@ Make sure air bubbles [A] are coming up from all six filer ports. ‘OLeave the container this way for 5 minutes or longer. NOTE lf no air bubbles are coming up from a filer port tap the botiom of the bottle two oF three times. Never rerave the conliner from the boatiery, ‘CAUTION Fl until the container is completely emptied. (@Bo corain that ail the electrolyte has flowed out. {@Tap the bottom the same way 25 above if there is any electrolyte left inthe container, Now pull the container gently out ofthe battery. @Let the battery sit for 20 minutes. During this time, the electrolyta permeates the special separators and the gas generated by chemical reaction is released. ‘@FFit he strip of caps [A] tightly into the fille ports unt the strip is at the same level as the top of the battery NOTE ©Do net hammer. Press down evenly with both han CAUTION, ‘Once you install the strip of caps alter filing the batiery, never remave it, nor add any water or electrolyte. () ntl Charge While a maintenance free battery can be used after ony filing with electrolyte, 2 battery may not be able to sufficiently move a starter motor to start an engine in the cases shown in the table below, where an initial charge is required before use. However, if a battery shows a terminal voliage of higher than 12.5 V after 10 minutes of filing (Nave 1), no initial charge is necessary. Condition requiring intial charge (Charging method ‘At low temperatures (lower than 0°C) (N) 09A x 2 ~ 3 hours (P12 x 2 ~ 3 hours Battery has been stored in high temperature and humidity. ‘Seal has been removed, or broken — peeling, tear or hole. (if you did not hear the sr-sucking sound "Shoosht” as you removed the seal (N)09A x 15 ~ 20 hours Battery a8 old as 2 years or more after manufacture. (P) 1.2.4 x 18 ~ 20 hours Battery manufacturing date is printed on battery te. Example) 12 98 Day Month _Year_Mig. location [Note 1: Terminal voltage ~ To measure battery terminal voltage, use @ digital voltmeter. (WN): ZX750N (P): 2X750P |1-16 GENERAL INFORMATION (V) Precautions 1) Noneed of topping-up No topping-up is necessary in this battery until it ends isi add water is very dangerous. Never do that, 2). Refreshing charge fan engine will not star. 2 horn sounds weak, or lamps are dim, it indicates the battory has been discharged. Give refresh charge for § to 10 hours with charge currant shown in the specification (see the Electrical System chepter). When a fast charge is inevitably required, do it following precisely the maximum charge current and time conditions indicated on the battery, under normal use, Forcibly prying off the sealing olug 10 CAUTION ] This batlery is designed to sustain no unusual deterioratior If refresh-charged according to the method specified above. | However, the battery's perlormance may be reduced noticeably # charged under conditions other than given above, Never remove the sealing plug during refresh charae. by chance an excessive amount ol gas is generated due lo overcharging, the safety valve operates to keep the battery sale. 3) When you do not use the motoreycle for months Give 2 refresh charge before you store the motorcycle and store it with the negative lead removed. Give a refresh charge once a month during storage. 4) Bottery life Ifthe batery will not stant the engine even after several rekesh charges, the battery has exceeded its useful it. (Provided, however, the vehicle's starting system has no problem.) fe. Replace Keep the battery away from sparks and open flames during charging, since the battery gives off an explosive gas mixture of hydrogen and oxygen. When using a battery charger, connect the battery to the charger before turning on the charger. ‘Thie procedure prevents parks at the hatery tarminale which eanle ignite any battery gases. No fire should be drawn near the battery, or no terminals should have the tightening loosened. ‘The electrolyte contains sulluric acid. Be careful nat lo have It touch your skin or ayes. Wf touched, wash Itor with liberal amount of water. Get medical attention if severe. (Vi Interchangeability with Ordinary Battery ‘A maintenance free batter can fully display its performance only when combined with a proper vehicle electric system, “Therefore, replace a maintenance free battery only on a motorcycle which was originally equipped with a maintenenee free battery Be careful, if @ maintenance free battery is installed on a motorcycle which had an ordinary battery as eriginal equipment the maintenance free battary’s life will be shortened,Technical Information ~ Flat CR Slide Carburetor ‘The ZX75ON has flat slide carburetors. Throttle Mechanism: “The slides are Tefion coated and two rollers are located on each side Of the slide to reduce friction. The rollers are mounted on shielded ball bearings and the throttle shaft on saaled needle bearings. [A] Needle Bearing [C] Shielded Ball Bearing [B] Plastic Roller [D] Slide “The resulting reduction in effort to move the slides gives the rider very precise throttle contro. “The throttle links open the throttle valves progressively This makes. engine control ovsicr at low and mid-range and vehieln santenl sasiar ‘when riding on tight comers or wer roads. Accelerator Pumps: “Air, being lighter than fuel, accelerates away from the fuel when the throttle valve is quickly opened. When the air arrives at the combustion. ‘chamber, there's not enough fuel with itand a lean stumble or hesitation results. This is especially true of large-bore carburetors such as on the SXI50N. To combat this, tho “CR” carburetors have two ‘iaphragm-type accelerator pumps which shoot 2 stream of fuel down teach venturi toward the intake valves. This supplies an enriched fuel fixture that arrives at the combustion chamber with the 2 When the throttle ig suddenly opened, the pump rad linked to the throtts shaft pushes the pum diaphragm forcing the fuel fom the pump Chamber. The inlet check valve closes and the outiet check valve opens Sllowing fuel to spray from the discharge nozzle, As the diaphragm felaxes, the inlet valve opens letting fuel from the float bow! refil the pump chamber. The outlet check velve closes as accelerator pump pressure fas stopping fuel fram syphoning out the dischs-ge nozzle. TA] Pump Rod [D] Infet Check Valve [8] Pump Diaphragm [£] Outlet Check Valve Te]. Pump Chamber [F]_ Discharge Nozzle GENERAL INFORMATION 1-17 Theatte Opening Ar Fuel Ratio Ga Guip Doering with somterator pum a { leone —rieh Tine1-18 GENERAL INFORMATION Fuel Enricher: The fuel enricher provides @ richer mixture to the engine in order to improve throttle response at lower engine speeds and prevent misfiring when the throttle is quickly opened. ‘When the throttle is more than 3/8 - open and the engine is turning between 1 500 rpm and 5 000 rpm, the fuel enticher solenoid valve ‘opens and pressured fuel is available to the accelerator pump chamber. ‘The accelerator pump inlet check valve closes preventing enricher fuel ‘rom ficoding the float bow". Insteed, fuel passes through theaccelerator pump outet check valve and out the discharge nozzle. ‘The fuel flows as shown, [A] Ful Tank IF] Accelerator Pump [8] Fuol Pump Chambers [C] Fuel Gallery [G] Discharge Nozzles [0] Enricher Solenoid Valve [H] Throttle Switch [E) Enricher Jet (1) IC Igniter ‘The throttle switch sends a signal to the IC igniter when the throttle is more than 3/8 - open. The IC igniter senses the throtte switch signal and engine speed, and actuates the fuel enricher solenoid valve accord- ing te the conditions above, 2% 2 4 E | a % | 192 3 4 5 = spunea tastes Tk : try Fl at wake Fon ob comets ee ‘Acsleration Pimp Inet hecValve 1 tae i fereus seston ft ‘emp chamber Ra Oude Check Vale | Crowe ¥. High Spe Discharge Nocsle Circuit Main Feel Few <>: Ful Envicher Fuel FlowGENERAL INFORMATION 1-19 Technical Information - Side Camshaft Chain Positioning the cam chain on the right side of the cylinders enables all of the combustion paths from the aicbox to the exhaust pipe to be short and stright 28 shown, improving breathing efficiency and shortening the oylinder block. It snortens the crankshaft and improves its iid. It also allows the crankshaft camchain sprocket to be as small as possible, without effecting crankshaft strength. This permits the ccemnshaft sprockets to be as small as possible aso, allowing the cylinder head to be compact. The compact eylinder head reduces angine weight ‘and provides more freedom in the design ofthe frame. ‘Chain Tunnel Combustion Chambers Chain Tunnel \ \ Odd Middle Camshaft Chai Side Cemshatt Chain1-20 GENERAL INFORMATION Technical Information - Engine Lubrication System The ZX750N/P oil system has dual oil pumps, with one pump. (Sub-Cil Pump Rotor) [A] feeding pressurised oil to the oil ecoler and ‘the other (Main Oil Pump Rotor) (8] to the top end, crank, and transmission. However, the main oil pump rotor width, at a mere 14 mm, significantly reduces mechanical loss. This two-pump system helps ensure reliable lubrication by avoiding drops in oll pressure during extreme riding conditions. ‘To cool the oil, @ liquid-cooled oil cooler [A] is employed, which offers several advantages over the air-cooled type. First, having almost the same cooling capability, the liquid-cooled oil cooler is more compact than the air-cooled oil cooler, fitted easily in the engine, and helps easy maintenance of engine. Next since the cooler is installed right an the crankcase without cil hoses. there is litle chance (of a major oil leak and litte oil pressure drop in the cooler. [A] Liquid-cooled Gil Cooler [8] Hor oi {C] Cola O11 [D] Cold Coolant [E] Hot Coolant ‘The semi-dry sump system is designed to reduce oil stirring loss by keeping the oil from collecting in the crankcase below the crarkshaft and in the clutch. Baffles [A] and passages [8] are fitted in the crankcase below the transmission to collect the oil at once as it returns from the lubrication system, feeding it to the ol pump inlet [C] and away from the crankcase and clutch basket.Benifits: GENERAL INFORMATION 1-21 Technical Information - Connecting Rod Big End Nut Tightening “There are two methods for tightening connecting rod big end nuts: the elastle region fastening method and the plastic region fastening method. With the clastic region fastening method, bolt axial tension increases in proportion to mut rotation, tangle (bol strain} when the nut is tightened. Upon removel of torque, the bolt returns to its original length. ‘The clastic region fastening method hae been widely used because itis simple and the bolts can be retightened and reused Yield Point Elte Limit ~ Tightening Point Bolt Axial Tension 3 Loosen tet Region cet ae As Tension [Sy ut Rosson Anal (Bok Stain) However, the ZX750N/P use the plastic region fastening method for reduced connecting fod weight and increased fastening reiability. This is because the ZX750N/P's connecting rods are under very severe Conditions such as high engine speed and high horsepower. With the plastic region fastening method, the bolt is tightend beyond js yield point where bo't stn grows rapidly. Upon removal of torque, the bolt doesn't retum to original length any more and perrenent strain, Beyond the yield point, exial tension increases gradually compared to bott strain: axial tension varies less to variations of nut rotation angle than in the elastic region as shown. Here, axial tension corresponds to clamping foree (the actual pressure applied to the twa parts being botted together), and bolt stain conesponds to nut rotation angle or to tightening torque. From this, the plastic region fastening method provides more stable and higher axial tension, But the method is more sophisticated than Conventional torquing and requires precise assembly end disassembly procedures, Region | Tiohtening Point Permanent et ‘Nut tation Angie (Bolt Stain)1-22_ GENERAL INFORMATION Elastic Region ‘Smaller Variation in Axial Tension 2 Elastic Limit | : & | i B| baraer Yield Point : | Variation ' In Axial i Tension i Plastic Region Fastening Method y ‘Nut Rotation Angle (Bolt Stain} Elastic Region Fastening Method Work Notes: (©Be sure to clesn the bolts, nuts, and connecting rods thorcughly with high-flash point solvent, because the new connecting rods bolts, and huts are treated with an anti-rust solution. This solution contains hydrogen wnien could weaker igi wise bolls sucit as connecting rod bolts and lead to bolt breakage. Apply molybdenum disulfide grease to the upper inner surface of th connecting rod big end. This prevents the upper bearing insert from wear and corrosion from its slight sliding metion during op=tetion, (©Do not apply molybdenum disulfide creese, only engine oil-0 the inner ‘surface of upper and lower bearing inserts because molybdenum disulfide grease promotes sliding motion of bearing inserts. [A] Apply molybdenum disulfide grease [8] Do not apply grease and oil [C]_ Apply oil (OWith the plastic region fastening method, do not retighten and reuse ‘the bolts or the permanent strain accumulates and the bolts may break. Methods: (OThere are two methods of plastic region fastening. One is bolt length measurement method and the cther is a rotation angle method, Use ‘one of the following two. (1) Belt Length Measurememt Method (©This method is preferable because this is a more reliable way to tighten the big end nuss, though it requires @ point micrometer [A] and ccurnbersome work [8] Connecting Rod [C) Mark here with a punch [0] Nuts [E] Fit micrometer pins into punch marks (@To prevent seizure of the bolt threads, apply a small amount of engine oil to the threads.ENERAL INFORMATION 1-23 (2) Rotation Angle Method ‘@Frst, apply a small amount of engine oil to the threads [A end seating surface [8] of the nuts to get stable axial tension, ‘@Next, tighten the nuts to the specified torque (snug torqus) to seat the ‘threads and mating surfaces. Finally, point [A] Crankshaft [2] Gunnecting Noe Big End Nute [cla ighten the nuts the specified angle at to exceed the yield ®. 34 | el® ( WA "Specified Torque Tightening Point roma | o:Specified Angle Bolt Axial Tension ‘Nut Rotation Angle (Bolt Strain)1-24 GENERAL INFORMATION Technical Information - Swingarm The swingarm pivots are equipped with low-tiction needle bearings for smooth working. On the rightside is a ball bearing which supports the thrust loads and eliminates even slight lateral play of the swingarm. This strengthens swingarm Figicty, especially its torsional rigidity. offering the motorcycle easier anc smoother drive under severe riding conditions, ‘The pivot parts ere tightened against the frame in this order: the collar (8} and pivot sha‘t [E], the pivot nut [6], and the pivot locknut [A], so the pivot shaft (E] and ball bearing [F] can be installed without any frame deformation end eny aep. to the frame, This prevents seraping of the seating surfaces and possible gaps among the aluminum pivot parts a OKO TA] Swingarm Pivet Locknut [0] Sleeve [6] Swingarm Pivot Nut [8] Collar [E] Swingarm Pivot Shaft [H] Frame IC] Needle Bearings [FI Ball Bearing | Information - Alternator U ‘An sternator [A] with a regulator/rectifer built in is mounted on tha crankcase, behind the cylinder. The conventional alternator is installed (on the crankshaft end, Benefits are as follows: Shortened engine width offers larger banking angle and smalier inertia when turning the motorcycle, Th alternator ‘output is increased comparing with the conventional altematar owing to increased alternator capacity itself, increased akemator speed over the crankshaft sped, and the alternator cooling fan.Torque and Locking Agent ‘The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking ‘agent or liquid gasket Letters used in the “Remarks” column mean’ + Apply @ non-permanent locking agent to the threads. L GENERAL INFORMATION 1-25 ‘The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent-cleaned threads Basle Torque for Goneral Fasteners [Apply liquid gasket tothe threads Left-hand threads. Tinea ad ‘Apply molybdenum disulfide grease co) Nem [kom Feo ! Apply on alto the threads ord seating surfoca 7 aeTan iesoe0 ho : Apply arease- 6 33 ~78| 0.60 ~ 0.80 [52 ~ 69'n- jahter the. fostenes following the specitied : ee ae ee anos. sequence. 10 25~34| 26~35 | 190~25 + Apply silicone sealant 2 PARA Peed eae Stake the fastoners to prevent joosening “ Shel ite Sop lege os 1 Rleptacarions fate, 16 118 ~ 166]11.5~ 160) 83 ~115 18 | 165 ~ 225/170 ~ 230| 125 ~ 195 20 | 225~ 325, 23~33 | 165 ~ 240 Fastener Torque Remarks Nem | kg-m felb Fuel System: Vacuum Viave Drain Screw 10 0.0 Sinelb Cooling System: Water Hose Clamp Screws 25 0.28 2in-tb Water Pipe Bolt (Water Pump) 33 10 87 inl Coolant Air Bloedor Bolt (Wator Pump) an 10 87 in-lo Coolant Drain Plug (Water Pump) 98 10 87 in-tb Water Hose Fitting Boits (Cylinder) 98 10 87 in-tb Radiator Fan Switch 1s | 18 130 ss Water Temperature Sensor } 15 15 10 ss Water Pump Cover Bolts 98 1.0 87 in-lb Engine Top End: Spark Plugs 8 13 113 in-lb Air Suction Valve Cover Bolts 98 1.0 87 in-lb Cylinder Head Cover Bolts 98 1.0 87 in-to Pickup Coil Cover Bolts 38 10 87 in-lo L ‘Camshaft Chain Tensioner Mounting Bolts 12 12 404 in-Io L Camshaft Cap Bolts 12 12 404 in-Ib s Water Pipe Flange Bots (Cylinder Head) 12 12 104 in-1o ‘Water Hose Fisting Bolts (Cylinder) se | 10 87 in-tb Cylinder Head Bolts: M10 “4 | 45 S, 0 (Washer) Me 12 12 s Engine Damper Caver Bolts 28 10 t Rear Camshaft Chain Guide Bolt 25 25 Inlet Pipe Fittings 49 0.50 inlet Pipe Plugs 49 0.50 43 in-b Carburetor Holder Bolts 12 12 108 in-b Oil Pipe Bolt 98 10 87 in-tb1-26 GENERAL INFORMATION Fastener Torque Remarks N-m kg-m ft-lb Clutch Clutch Lever Pivot Bott 10 010 Clutch Lever Pivot Bolt Locknut 59 0.60 Starter Lockout Switch Screws 10 0.10 Clutch Slave Cylinder Bleed Valve 78 0.80 69 in-Ib Clutch Reservoir Cap Screws 18 0.15 13 inet Clutch Master Cylinder Clamp Bohs u 14 96 in-tb s Oil Filler Plug 150r | 01501 | 13in-lb or Hand-Tight|Hand-Tight | Hand-Tight Clutch Cover Botts 98 10 87 in-tb | L(3, Front) Clutch Cover Damper Bolts 59 0.60 52 in-lb L Clutch Hub Botts 26 25 180 E Clutch Spring Bolts 88 0.90 78 in-lb Clutch Hub Nut 130 135 98 R Clutch Housing Bolts, 78 0.80 69 in-Ib L Clutch Hose Banjo Botts 25 25 18.0 Engine Lubrication System: Oil Filler Plug 150r | 0450 | 13in-Ibor Hand-Tight| Hand-Tight | Hand-Tight Engine Drain Plug 20 20 145 Oil Fitter(Cartridge type) 98or | 100r | 87in-lbor | R,G(O- ring) Hand-Tight | Hand-Tight|Hand-Tight Oil Fitter Mounting Bott 25 25 180 L(Tap End) Oil Pan Bolts 98 1.0 87 in-Ib Oil Pressure Relief Valves 15 15 11.0 iE Oil Pressure Switch Terminal Bolt 15 0.415 13 in-lb Oil Pressure Switch 15 15 11.0 ss Oil Pump Bolts we | 12 104 in-to L Oi Cooler Bott 48 5.0 36 ° Oil Hose Clamp Screws 25 0.25 22 in-tb Oil Pipe Flange Bolts 98 | 10 87 in-tb Crankcase Main Oil Pessage Plugs 20 | 20 145 ss Alternator Shaft Oil Pipe Bott 12 12 104 in-Io i ‘Transmission Oil Pipe Holder Bolt (Right Side) | 12 12 104 in-Ib L Engine Removai/Installatior Engine Collar Bos 98 10 87 in-Ib Engine Mounting Locknuts 49 50 36 Engine Mounting Bolts and Nuts 59 60 43 Crankshaft/Transmission: Upper Altemator Chain Tensioner Pivot Bolt 12 12 104 in-ib L Upper Altemator Chain Tensioner Set Bot 12 12 104 in-Ib L Upper Chain Tensioner Locknut 25 25 18.0 Alternator Shaft Oil Pipe Bolt 2 12 104 in-Ib L Lower Alternator Chain Tensioner Botts 2 12 4104 in-Ib LGENERAL INFORMATION 1-27 Fastener Torque Remarks Nem | kg-m Felb Alternator Shai Beering Holder Bolts 12 12 | 108in-16 L Alternator Shaft Bolt 5 25 180 Camshaft Chain Guide Bolt 2% 28 180 Lower Crankcase Bolts © 9 44 45 3 | 98 (115mm) 27 28 20 2.8 (40mm, 46mm) | 25 25 180 Upper Crankcase Bolts 0 8 25 25 180 Engine Bresther Cover Bolts 98 10 87 in-Ib L Crankcase Main Oil Passage Plugs 20 20 145 ss ‘ransmission Oil Pipe Bolt (Right Sie) 12 42] 104 in-w L Connecting Rod Big End Nuts inthe text |= - = Battery Negative Lead Terminal Bolt 49 050 | 43intb Oil Pipe Flange Botts 98 10 87 in-lb Timing Rotor Bolt 25 25 180 Starter Clutch Holder Bolts 12 12 | 104in-tb L External Shift Mechanism Cover Screws 49 050 | 43in-b t External Shitt Mechanism Cover Bolts 98 10 a7intb | Gear Positioning Lever Bott 98 19 87 in-lb L Shift Shaft Retum Spring Pin (Bott) 42 43 3 L Neutral Switch Screw 38 040 | 35in-b Shift Drum Bearing Holder Bolts 12 12 | 104 in-tb L Shift Drum Cam Holder Bolt 12 | 12 | 10¢inb L Pickup Coll Cover Bots 98 10 97 in lb L Wheole/Tiros: . Front Axle Clamp Bolts 20 20 jas Front Axle Nut 145 150 110 Fear Axle Nut 145; 9 | 110 Final Drive: Engine Sprocket Cover Bolts 98 10 87 in-lb Engine Sprocket Nut 125 130 9 ° Fear Sprocket Nuts 74 18 86 Rear Sprocket Studs - - - L Rear Axle Nut 145 150 110 Brakes: Bleed Valves (2X750N) 54 oss | 48 in-tb Bleed Valves (2X750°) 78 080 | 69in-b Brake Hose Banjo Bolts 25 25 180 Broke Lever Pivot Bolt 10 010 9 inl Broke Lever Pivot Bolt Locknut 59 060 | 52in-tb Front Brake Reservoir Cap Holder Screws 15 ois | 13inb Front Broke Light Switch Screws 10 0.10 9 inelb Front Master Cylinder Clamp Bolts 1 1 $8 in-lb s Front Brake Hose Jeint Mounting Bolts 68 070 | 61 into Front Caliper Mounting Bolts 34 35 | 28 Front Brake Disc Mounting Bots 23 23 165 Front Caliper Assembly Botts (2X750N) 23 23 168 3 Front Caliper Assembly Bolts (2X750P) 21 24 150 | Front Brake Pad Pin (2X750N) 18 1s | 130 Front Broke Pad Pin Plug (2X750N) 28 028 | 22inlb Front Brake Pad Spring Bolts (2X750P) 29 030 | _26in-b1-28 GENERAL INFORMATION Fastener Torque Remarks Nem kg-m | ft-lb Rear Brake Reservoir Bolt 69 0.70 61 in-tb Rear Brake Hose Holder Bolts 69 0.70 61 in-ib Rear Brake Disc Mounting Bolts 23 | (23 165 Rear Caliper Mounting Baits 2% | 25 180 Rear Master Cylinder Mounting Boks 2 | 23 165 Rear Master Cylinder Push Rod Locknut ww | 18 130 Rear Caliper Assembly Bolts (ZX750N) 32 | 33 24 i Rear Caliper Assembly bolts (ZX750P) 29 30 22 Rear Brake Pad Pin (2X750N) 18 13 130 Rear Brake Pad Pin Plug (ZX750N) 25 0.25 22 in-Ib ‘Suspension: Upper Front Fork Clamp Bolts 2 24 150 Lower Front Fork Clamp Bolts (2X750N) a 24 150 Lower Front Fork Clamp Bolts (ZX750P) 28 29 2 Front Fork Top Plugs 23 23 165 Piston Rod Nut 15 15 11.0 Front Fork Bottom Allen Bolts 39 40 29 L Front Axle Clamp Bolts 20 20 145 s Rear Shock Absorber Nuts 59 60 43 Rear Shock Absorber Upper Brackets Nut 59 680 43 ‘Swingarm Pivot Shaft 20 20 145 s Swingarm Pivot Nut 98 100 R s ‘Swingarm Pivot Locknut 98 100 D s Uni-Trak Rocker Arm Nuts 59 60 3 Tie-Rod Nuts 59 60 43 Steering: Steering Stem Head Nut 54 55 40 Steering Stem Nut 43or | 0500r | 43in-ibor Hand-Tight| Hand-Tight | Hand-Tight Handlebar Bolts 34 35 25 L Handlebar Holder Bolts 23 23 165 Handlebar Holder Position Bolts 98 10 87 in-Ib ‘e Handlebar Weight Screws - = - L Handlebar Switch Housing Screws 34 0.35 30 in-Ib Frame: Rear Frame Bolts and Nuts a8 45 33 Footpeg Holder Boits (Right. Left) 34 35 25 L Side Stand Bracket Bolts 49 50 36 Electrical System: ‘Spark Plugs 13 13 113 in-lb ‘Alternator Mounting Bolts 25 25 180 ‘Alternator Coupling Nut 54 55 40 Alternator Assembly Nuts 44 045 39 in-lb Altemator Bearing Retainer Screws 25 | 025 22in-b | Altemator Housing Altemator Regulator Screws 34 035 30 in-tb Alternator Lead Terminal Screws 34 035 30 in-Ib Alternator Brush Screws 34 035 | 30in-Ib Aitemator Cover Screws 34 0.35 30 in-Ib Pickup Coil Cover Bolts 98 1.0 87 in-lb L Pickup Coil Bolts 78 0.80 69 in-Ib —GENERAL INFORMATION 1-29 Fastener Torque Remarks Nm |_kg-m ftib Timing Rotor Bott 25 28 18.0 Starter Motor Terminal Locknut " 14 96 in-Ib Starter Motor Terminal Nut 49 050 43 in-Ib Starter Relay Terminal Bolt 49 050 43 in-Ib Starter Motor Through Bolts 59 0.60 52 in-lb Starter Motor Mounting Bolts 98 10 87 in-lb Handlebar Switch Housing Serews 34 035 30 in-b Radiator Fan Switch 18 48, st 0018.0 ss Water Temperature Sensor 15 15 11.0 ss Oil Pressure Switch Terminal Bolt 15 015 13iin-tb Oil Pressure Switch 16 15 11.0 ss Neutral Switch Screw 39 0.40 35 in-lb Starter Lockout Switch Screws 10 0.10 Gin | Side Stand Switch Screws - - - L1-30_GENERAL INFORMATION Special Tools and Sealant Inside Circip Pliers §7001-143 Piston Pin Puller Assembly: 6701-910 900 Fuel Level Geuge: 67001-1017 —— Oil Pressure Gauge Adapter, PT : 57001-1033 @ Oil Seal & Bearing Remover: 57001-1058 SS Valve Spring Compressor Assembly: 5701-241 Head Pine Outer Race Press Shaft; 57001-1075 "SGENERAL INFORMATION 1-31 Heed Pipe Outer Race Oriver: 57001-1077 Valve Seat Cutter Holder Bar: 57001-1128 @ = Steering Stem Nut Wrench: 57001-1100 Beating Driver Set: 57001-1128 Valve Seat Cutter, 45" — 027.5: 57001-1114 Valve Spring Compressor Adapter, 922: 57001-1202 © Ga Valve Seat Cutter, 32° - 028: 57001-1118 Fork Outer Tube Wetght: 57001-1218 © Valve Seat Cutter, 60° ~ 980: 57001-1123 Jack: 67001-1238 i ©1-32_GENERAL INFORMATION Clutch Holder: §7001-1243 Pilot Serow Adjuster, C: 57001-1292 WS Oil Filter Wrench: 57001-1248 Fork Cylinder Holder. 67001-1297 = Bearing Remover Shaft 57001-1265 Fork Piston Rod Puller, M10 x 1.0: 57001-1298 S | SS a Carburatar Drain Plug Wrench, Hex 3: §7001-1269 Compression Gauge Adapter, M10 X 1.0: 57001-1317 SS Fork Oil Level Gauge: 67001-1290 Valve Seat Cuttor Holder, 4.5: 57001-1330 “Ra —GENERAL INFORMATION 1-33 Valve Guide Arbor, 04.5: 57001-1331 ‘Steering Stem Bearing Driver Adapter, 57001-1345 SS Valve Guide Reamer, 04.5: 57001-1333 Boaring Remover Head, 025 x 028: 57001-1346 <, & | Fork Spring Compressor: 57001-1338 Socket Wrench: 57001-1347 ay Fork Oil Seal Driver, 43: 57001-1340 Crankease Splitting Tool Assembly: 67001-1362 | “es Steering Stem Bearing Driver: 67001-1344 ‘Vacuum Gauge: 57001-1369 SQ1-34_GENERAL INFORMATION Socket Wrench: §7001-1370 Vacuum Gauge Bolt Washer: 92022-304 _& G Pilot Screw Adjuster Adapter, 05: 57001-1372 Spark Plug Wrench, 16mm: 92110-1154 S ep Pilot Screw Adjuster Driver: 87001-1373 Vacuum Gauge Bolt: 92150-1181 “E> “Gr Pressure Cable Luber: K56018-021 Hand Tester. 57001-1394 €e Fork Cylinder Holder: 67001-1396 Kawasaki Bond (Silicone Sealant): 56019-120 — — 4GENERAL INFORMATION 1-351-36 GENERAL INFORMATION Cable, Wire, and Hose Routing ‘Speedometer Cable Main Hamess Loft Headlight City Light (Europe Models) Fight Heediight Diode (Europe Models except UK Model) Right Tum Signal Light Leads Loft Turn Signal Light Leads High Beam Relay (AS and UK Models) 10. Choke Cable (Run the choke cable outside the clutch hose) (AS): Australia (UK): UK 11. Brake Hose 12, Front Fork 13. Throttle Cables 14, Clutch Hose 16. Choke Cable Adjuster 16. Separate the clamp by 15 ~ 20mm ‘rom the adjuster backward. 17. Run the throttle cables on the air vent pips. Fun the choke cable under the air vent pipe. 18 ClampGENERAL INFORMATION 1-37 Front Sub Harness Meter Unit Left Handlebar Switch Right Handlebar Switch Front Fork lgnition Switch Lead ‘Water Temperature Sensor Lead Battery Ground (-) Lead Chassis Ground Led Rear Brake Light Switch Lead Band (Rubber Protector on the Hemess) Fuel Pump Relay Lead ‘Accessory Leeds IC Igniter Connectors ‘Tur Signal Relay Rear Right Turn Signal Light Leed . License Plate Light Lead Tail/Breke Lights Lead Roar Left Turn Signal Light Lead Starter Rolay Lead Junction Box: . Battery Positive (+) Lead | Starter Motor Lead |. Fuel Pump Lead Insert the harness clamp into the hole inthe ignition coil bracket Insert the harness clamp into the hole in the radiator bracket. Radiator Fan Switch Leacs Fan Motor Lead 1. Neutral Switch Side Stand Switen 2, 43 Ignition Coll Alternator Solenoid Valve (ZX750N) Throttle Switch (ZX75ON) Pickup Coil #1, #4 Ignition Coil Clamp Band1-38 GENERAL INFORMATION Left Side View: 1. Hon 5 Tum Signal Rolay 8. Install the chassis ground terminal 2. Radiator Fan Switch 6. Fuel Pump Relay with the rear fender. 3. #2,#83 lanition Coll 7.1, #4 Ignition Coil 10. Tighten the clamp with the left side 4. Startor Relay & IC igniter mounting bolt 11, BandGENERAL INFORMATION 1-39 peeps Vacuum Vaive 6. Ignition Coil Bracket 11, Clamp Vacuum Switch Valve 7. Solenoid Valve 12, Band #1, #4 Ignition Coil 8. Starter Motor -cad #2, #3 Ignition Coil 8, Bend the startr motor lead terminal down, 10. Carburetors Damper1-40 GENERAL INFORMATION @c 1. Vacuum Valve 2. Vacuum Hoss 3. #3 Vacuum Fitting 4. Carburetor Ait Vent 5. Damper 6. Air Cleaner Housing @o 7. Intake Silencer 12, Run the vacuum hose inside the 8. Vacuum Switch Valve clamp on the #2 carburetor holder. 9. Baffle Plate 13, Inlot Pipe Plug 10, The white mark points upward. 14. Clamp 111, Run the vacuum hose between the #1 and #2 carburetor holders.GENERAL INFORMATION 1-41 10, Fusl Hose (Fuel Pump -> Carburetors / Run the let side hose of 4. Fuel Tank Drain Hose ‘the carpuretor fant side the breather hose.) 2. Run the drain hose inside the bracket. 11. ‘Idle Adjusting Screw Bracket 3. Fuel Hese (Fuel Tank — Fuel Filter) (Rum the idle adjusting cable under the main harness) 4. Fuel Fier 12, Air Cleaner Drain Hose 5. Damper 113. Run the hase inside the clutch hose and hold it by 6. Fuel Hose (Fuel Filter -+ Fuel Pump) tho clamp. 7. Fuel Pump and Hoider 14. Clutch Hose 8. Spring (for guard ofthe fue! hose) 15. Camp 9, The clamp knob points upward. 16. Tha clamp knob peints downward,1-42 GENERAL INFORMATION eynsny say usa due coi teenGENERAL INFORMATION 1-43 | (AR, FG, FR, |T, KR, NL, ST, UK Models) Coolant Reserve Tank Roserve Tank Cover Reserve Tank Overflow Hose Reserve Tank Hose Clamp ‘Thermostat Housing Coolant Filter To Carburetor Coolant Valve (0, Install the valve so that the stepped side is downward 11. Water Pump1-44 GENERAL INFORMATION Front Brake System Rear Brake System Brake Hose Joint Front Brake Caliper Front Brake Master Cylinder Front Brake Reservoir Upper Lever Line of Brake Fluid @ ear Brake Caliper Rear Brake Master Cylinder lear Brake Reservoir Clamp BandGENERAL INFORMATION 1-45 ZX75ON: 2x750P: aeeromaepe Seat Lock Seat Lock Cable Pad Seat Cover Far Seat Lock Tail/Brake Lignt Tail/Brake Light Bracket Tail/Brake Light Lead Fear Left Turn Signal Light Lead Clamp1-46 GENERAL INFORMATION Evaporative Emission Control System (Callfornia) Rear View 1. Vacuum Valve 2. Vacuum Switch Valve 3. Separator 4. Canister 5. Purge Hose (Green) | 6. Vent Hose (Yellow) 7. Vacuum Hose (White) 8 Breather Hose (Blue) 8. Return Hose (Fed) 50. Fuel Tank 11, To #3 Vacuum fiting 12. To #1, 4 Vacuum Fittings 13. To #2 Vacuum Fitting | 14. To Canister 15. Clamp (Vent Hose and #3 Spark Plug Lead) 16. Run the vent hose under the harness. 17. Bend (Starter Motor Lead) 18. Run the purge hose at the ‘corer of the battery. 19. Band (Purge Hose) 20, Run the purge hose under the throttle cables and #2 spark plug lead 21. Clamp (Purge Hose and #1 ‘Spark Plug Lead) 22, To Intake Silencer 23. Run the vent hose outside the ames. 24, Clamp. 25, Band ‘The hoses are not to tight by bands.GENERAL INFORMATION 1-47 Evaporative Emission Control System (California) 1. Vent Hose (Yellow) 2. T-type Fitting 410. Rum the vent hese from under the hamess 3. Install the fiting at bottom af the vent hoses (Yellow) 10 inside. 4. Catch Tank 41, Bands (Vent Hose and Harness) 5. Install the eatch tank inside the frame. 12, Run th vent hose under the harness. | & Drain Plug 43, Canister 7. Clamp 8. Bands (Starter Motor Cable) Bands (Purge Hose, Green)1-48 GENERAL INFORMATION Evaprative Emission Control System (California) Vacuum Valve Vacuum Hose 48 Vacuum Fitting Carouretor Air Vent Air Cleaner Housing Canister Damper Baffle Plate Intake Silencer Vacuum Switch Valve ‘The white mark points upward. Fun the vacuum hose between the #1 and #2 carburetor holders. Run the vacuum hose inside the clamp on the 42 carburetor holder. Separator ClampFUEL SYSTEM 2-1 Fuel System Table of Contents Exploded View a nD Air Cleaner ‘Specifications i. 28 Housing Removal Throttle Grip and Cables, 28 Housing Installation on Free Play Inspection... 28 Element Removal Free Play Adjustment .. 28 Cable Installation... 28 Cable Lubrication 2-9 Choke Cable. BNO Froe Play Inspection. ennsens Free Play Adjustment. 2-10 Cable Installation see AD Cable Lubrication 2-10 Carburetors. 211 dla Speed Inspection... 21 Idle Speed Adjustment. 211 ‘Synchronization Inspection (2ZX750N) 211 Synchronization Adjustment (2X7EON) 2-42 Synchronization Inspection (2X750P) Synchronization Adjustment (2X750?) Service Fuel Level Inspection... 214 Service Fuel Level Adjustment. Fuel Systm Cleantinss Inspection 2.15 Carburetor Removal. 2.18 Carburetor installation 248 Carburetor Disassembiy/ASSEmBY.onscs on 218 Carburetor Separation/ Assembly. DAT Carburetor Cleaning wn 247 Carburetor Inspection DAB High Attude Performance Adjustment (US mode!) rn BAD Coolant Filtee Cleaning (AR, FG, FA, IT, KR, NL, ST, UK) 2419 Element Installation é Element Cleaning and Inspectio Oil Draining... oo Fuel Tank Fuel Tank Removal Fuel Tank installation. Fue! Tank Inspection Fuel Tank Cleaning. Fual Tap Removal Fuel Tap Installation Fuel Tap Inspection Fuel Pump, Fuel Filter... Fuel Pump Removal... Fuel Pump Installation Fuel Fiter Removal... Fuel Filter Installation Fuel Pump Inspection Fue! Filtor Inspection... ‘Vacuum Valve. Vacuum Valve Inspection Evaporative Emission Control System (California Model Only) = Parts Removel/Installation so..creeneennnne2-28 Hose Inspection. ‘Separator Inspection Separator Operation Test. Canister Inspection. [202.2 FUEL SYSTEM Exploded View ZX75ON:FUEL SYSTEM ‘ZXTBO-N: 2 A) 4. Throttle Cable (accelerator) q 2, Thotte cable (deceleraton) XH @QY@ 3. Choke Cable ‘ 4. Pilot Screw 5. Pilot (Siow) Jet 6. Main Jet 7. Plug (US, ST) a Starter Jet 8. Main Nozale 10. Jet Needle 11. Ascelerator Pump 12. (US, CN) Models 13. Fuel Ervicher Solenoid Vaive 414. Other than (US, CN) Models G: Apply grease. GL: Apply cable lubricant. Switertand United States Canadacoe bmn“ Sages aides vege 5)FUEL SYSTEM 2-3 ‘zx780P G: Apply grease, | GL: Apply cable lubrcam. |. Throttle Cable (accelerator) 9: Thrott! Cable (decolerator) |. Choke Cable Pilot Screw Pilot (Siow) Jet Air Bleed Pipe Main Jet Plug (US, ST) Jet Needle i ST: Switzerland © US: United States \\ ? ® 9 "2-4 FUEL SYSTEMFUEL SYSTEM 2-52-6 FUEL SYSTEM Specifications Item Standard Throttle Grip and Cables: ‘Throttle grip free play 2~3mm Choke Cable: Choke cable free play 2~3mm Carburetors (ZX750N1, N2): Make, type Idle speed. Pilot screw (turns out) Synchronization vacuum Service fuel level Float height Main jet Main air jet Main nozzle Jet needie mark Jet needie clip position Pilot jet (stow jet) Pilot air jet (slow air jet) Starter jot Throttle valve cutaway High Altitude Carburetor Spectticavions (US) Pilot jet Main jet Carburetors (ZX750P1, P2): ‘Make, type Idle speed Pilot screw (turns out) Synchronization vacuum Service fuel level Float Height Main jet Main air jot Needle Jet Jet needle mark Pilot jet (slow jet) Pilot air jt (slow air jet) Starter jet Throttle valve angle High Altitude Carburetor Specifications (US) Pilot jot Main jet KEIHIN, FVK-D41 x4 1100 + 50 r/min (rpm). (AR, CA, FG) 1300 + 50 r/min (rpm) 2-%%, (CA, US) -- 2.7 kPa (2 cmHg) or less difference from 44 carburetor 3.1 mm above the mark 942mm #200 (1, 4 cyl), #210 (2, 3 cyl) 450 +6 N3GF, (US) N3HC 4th groove from top (us) ~~ #82 #140 #55 23mm #40 (92084-1125) ¢ #195 (1, 4 cyl. 92063-1478) #200 (2, 3 eyl. 92063-1417) KEIHIN, CVK-D38x4 1100 & 50 r/min (rpm), (AR, CA, FG, ST) 1300 £ 50 s/min (rpm) 1-% (CA, ST, US) == 2.7 kPa (2 cmHg) or less difference between two cylinders. 5 1 mm below the mark 1342mm #170 (1, 4 cyl), #180 (2, 3cyl) #50 +6 niga #8 #125 442 ww #82 (92064-1117) #165 (1.4 cyl. 92063-1347) #175 (2, 3 cyl, 92063-1387)FUEL SYSTEM 2-7 Item’ Standard Air Cleaner Element Oil: Grade SE, SF, or SG class Viscosity ‘SAE30 (AR): Austria Model (ST): Switzerland Model (CA): Califomia Model (US): U.S. Mode! (FG): Germany Model ‘Special Tool ~ Fuel Level Gauge: 57001-1017 Carburetor Drain Plus Wrench, Hex 3: 57001-1269 Fork Oil Level Gauge: 57001-1290 Pilot Serew Adjuster, C: 57001-1292 Pilot Screw Adjuster Adapter, 5: $7001-1372 Pilet Serew Adjuster Driver: 57001-1973, Vacuum Gauge: 57001-1369 Vacuum Gauge Bolt 92150-1181 (as required) Vacuum Gauge Bolt Washer: 92022-004 (as required) Pressure Cable Luber: KSoU19-0212-8 FUEL SYSTEM Throttle Grip and Cables Free Play Inspection ‘Chock the throte grip roo play [A] >If the fee play is incorrect, adjust the throttle cable. Throttle Grip Free Play Standart: = 2~ 3mm Free Play Adjustment Loosen the locknut [A]. Tum the adjuster [B} until the proper amount of free play can be obtained ‘eTighten the locknut securely “if the proper amount of froe play cannot be obtained by using the adjuster only, use the adjusters atthe carburetors side. ‘@Loosen the locknut, and screw the adjuster at the upper end of the accelerator cable all the way in ‘Tighten the locknut securely. @ Remove: Fuel Tank (2X75ON, soe Fuel Tank Removal) Air Cleaner Housing (ZX750P, see Air Cleaner Housing Removal) ‘@ Loosen the locknuts [A] at the middle part of the accelerator cable. ‘um the adjusters [B] unt the proper amount of throtle grip free play is obtained Tighten the locknuts securely. IF the proper amount of free play can not be obtained in tre adjustable range of the adjuster, use the adjuster at the upper end of the acceler- ator cable again. Cable Instaltation @ instal the throttle cables in accordance with Cable Routirg section in General Information chapter. @ instal the lower ends of the throttle cables in the cable bracket on the carburetor after installing the upper ends of the throttle cables in the rip. ‘@A‘tor installation, adjust each cable properly As Operation with Incorrectly routed or Improperly adjusted cables ‘could result In an unsate riding condition.FUEL SYSTEM 2-9 Cable Lubrication Whenever the cable is removed, lubricate the throtle cable as follows: ‘@ Apply a thin coating of grease to the cable lower ends ‘@ Lubricate the eable with a penetrating rust inhibitor. ‘Special Too! Pressure Cable Luber: KS6019-021 [A]2-10 FUEL SYSTEM Choke Cable Free Play Inspection ‘® Check thatthe choke inner cable slides smoothly by moving the choke lever (Al to the front and rear. “If there is any imegularity, check the choke cable play [8] ‘@Push the choke ever all the way to the front. ‘@Check choke cable free play (Al. [©Determine the amount of choke cable play atthe choke lever. Pull the choke lever until the starter plunger lever [B] at the carburetor touches the starter plunger [C]; the amount of choke lever lower end travel is ‘the amaunt of choke cable play. 2 the free play s incorrect, adjust the choke cable. Choke Cable Free Play ‘Standard: = 2~3mm Free Play Adjustment ‘@ Remove the fuel tank and air cleaner housing (soe Fuel Tark Removal and Air Cleaner Housing Removal) @ Loosen the locknut [A]. and turn the adjuster [8] until the cable has the proper amount of free play. ‘eTigmten the locknut securely. Cable Installation @ Install the choke cable in accordance with the Cable Routing section in the General Information chapter ‘@ After installation, adjust the cable propery. Cable Lubrication Whenever the choke cable is removed, lubricate the choke cable as, follows: ‘@ Apply a thin coating of grease to the cable upper end. ‘© Lubricate the eable with a penetrating rust inhibitor. ‘Special Tool ~ Pressure Cable Luber: K56019-021 [A]Carburetors, Idle Speed Inspection ‘CAUTION For ZX7SON model, do not open and close the throtle excessively. ‘The accelerator pump can flood the engine, and cause starting dificuty- (Start the engine and warm it up thoroughly. CAUTION For ZXTSON model, do not open and close the throttle excessively when warming the engine. The accelerator pump can flood the engine, and cause the spark plug fouling. ‘eth the engine idling, turn the handlebar to both sides. 4e1f handlebar movement changes the idle speed, the throtte cables may be improperly adjusted o incorectly routed, or damaged. Be sure to correct any of these conditions before riding (see Ceble Routing section in General Information chapter), ‘Operation with Improperly adjusted, incorrectly routed, or damaged cables could result In an unsafe riding condition ‘echeck idle speed, “i the idle speed is out ofthe specified range, adjust it lle Speed ‘Standard: 1,100 + 50./min (rpm) (Caltoria, Swiss, Austria and Germany Modets) 4,300 +50 imi (rpm) Idle Speed Adjustment ‘eStart the engine and warm it up thoroughly. ‘@ Turn the adjusting screw [A] unti the ile speed is eome=. 2.0pen and close the throw a few times to make sure that the idle ‘speed is within the specified range. Readjust if necessary. ‘Synchronization Inspection (2X750N) ‘@Remove the fuel tank (see Fuel Tank Removal). {@Connect a fuel tank to the carburetors with a suitable hose (@Screw in the idle adjusting sorew about three threads. This is the point ‘where tha adjusting screw is about to move the pulley. (CAUTION. ‘Do not open and close the throttle excessively. The accelerator pump can flood the engine, and cause starting ditfculy. FUEL SYSTEM 2-112-12 FUEL SYSTEM ‘eStart the engine and warm it up thoroughly. ‘CAUTION Do not open and close the throttle excessively when warming the ‘engine. The accelerator pump can flood the engine, and cause spark plug fouling. (eCheck idle speed. ‘@ Remove th gir cleaner housing and the carburstors. {@For the models other than the California medel, remove the inlet pipe plug [A] on the #2 cylinder head, and install the vacuum gauge bolt (62150-1161) and washer (92022-304). ‘@ Attach the vacuum gauge [A] to the bolts on the cylinder head. ‘Special Tool ~ Vacuum Gauge: 57001-1969 ‘© install the carburetors ‘@Star the engine and lett idle to measure the carburetor intake vacuum, >If the vacuum is incorract, adjust the synchronization. ‘Carburetor Synchronization Vacuum Standard: Less than 2.7 kPa (2 cmbig) difference from the #4 carburetors. ‘Synchronization Adjustment (ZX750N) ‘@Remove the top covers [A] @Do not remove the #4 top cover [B). ‘@ Loosen the locknuts [A] and tum the adjusting serews [8 (OTurning in the balance adjusting screw closes the throttle valve. (@Tighten the locknut ‘CAUTION Do not tamper withthe adjusting screw of the #8 carbureter which is the standard for synchronization. o not turnin the adjusting screws too far. Do not make tre throtle valve to carburetor bore clearance less than the standard carburetor. This upsets the throttle pulley position, and the standard (#4) carburetor will not isle property. JFIF the carburetor synchronization cannot be obtained by using the adjusting screws, remove the carburetor and check for din, blockage, or throttle valve clearance. ‘OAdiust each clearance [A] between the throttie valve (B] and the bottom [C] of the carburetor bore so thet the clearence is the same as the #4 carburetor’ clearance using the adjusting screws atove.FUEL SYSTEM 2-13 (©.Check the pilot screw settings using a screwdriver. ‘@ Check the carburetor synchronization again. NOTE Do not turn the pilot screws carelessly. You may cause poorrunning at low engine speed. ‘@For the models other than the Califomia model, remave the vecuum ‘gauge boits and instal the inlet pipe plug and washer. eCheck idle speed. ‘Synchronization Inspection (2X750P) ‘@ Remove the fuel tank (see Fuel Tank Removal). ‘@Suppiy fuel to the cerburetors with an auxiliary fuel tenk: |Start the engine and warm it up thoroughly. ‘@Check idle speed ‘@For the models other than the California model, remove the inlet pipe lug on the #2 cylinder head, and install the vacuum gauge bolt (92150-1161) and washers (9202-304). ‘@Artach the vacuum gauge [A] to the bolts [8] on ¢ Special Tool ~ Vacuum Gauge: 57001-1359, ‘e-star the engine and lett idle to measure the carburetor intake vacuum. $f the vacuum is incorrect. adjust the synchronization cvinder heed. Carburetor Synchronization Vacuum ‘Standard: Less than 2,7 kPa (2 cmH) difference between any two carpurewors. ‘Synchronization Adjustment (ZX750P) (@ Turn the adjusting serew to synchronize the carburetors (OFirst synehronize the left two and. then the right two cerburetors by means of the left and right adjusting screws [A.B]. Then synchronize the leit two carburetors ond the right two carburetors using the center djusting sorew [C] “kf the carburetor synchronization cannot be obtained by using the adjusting screws, check for dirt or blockage, and then check the pilot screw settings, Special Tool ~ Pilot Serew Adjuster, C: 57001-1292 Pilot Screw Adjuster Adapter, 5: 57001-1372 Pilot Screw Adjuster Driver: 57001-1373 ‘eCheck the carburetor synchronization again NOTE (©Do not turn the plot screws carslessly during carburetor synchroni- zation. You may cause poor running at low engine speed. ‘eFor the models other than the California model, remove the vacuum ‘gauge bolt and install the inlet pipe plug and washer. ‘© Check idle speed.2-14 FUEL SYSTEM ‘Service Fuel Level Inspection EIS ‘Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make s the area Is well-ventilated and free from any source of flame or sparks; this Includes any appilance with a plot light. ‘@Situate the motorcycle so that it is perpendicular to the ground. ‘@ Remove the fucl tank (soe Fuel Tank Removal). @Prepare an auviliary fuel tank and connect the fuel hose to the carburetors. (@ Prepare a fue! hose (6 mm out diameter and about 300 rn long) ‘© Connect the fuel level gauge [A] to the carburetor float bew! with the fuel hose, ‘Special Too! ~ Fuel Level Gauge: 57001-1017 @Hold the gauge vertically against the side of the carburetor body 0 ‘that the middle line (ZX750N) [B], top line (ZX750P) [C] is several millimeters higher then the mark [D] on the carburetor body. (@Feod fuel to the carburetor, then tuen the carburetor drair plug out 9 few tums, ‘@ Wait until the fuel level in the gauge setts. ‘@Keoping the gauge vertical, align the middle line or top line with the mark. NOTE 000 nat lower the mide ine oF top lina below the mark ofthe carburetor Body. lithe gauge is lowered and then rained again she {uel level measured shows somewhat higher then the actual fish fevel. Ifthe gauge i lowered too fr, dump the fuel ints a suitable cantainer and stant the procedure over again. ‘@ Read the fue ove [E] inthe gauge end compare tothe specification ‘@Screw in the carburetor dain plug. {©5top feeding and remove te fu! level geuse. I the fuel love! s incorect, aust it (see Service Fuel Level Adjust ment) ‘Service Fuel Level Standard: 3. 1 mm above the mark on the craburetor body 5 +1 mm bolow the mark on the carburetor body Service Fuel Level Adjustment ‘Gasoline ls extremely flammable and can be explosive uncer certaln conditions. Tur the ignition switch OFF. Do not smoke. Make sure | tho area 1s wollventlated and {ree from any source of flame or sparks; this Includes any appilance with a plot ight. ‘@ Remove the carburetor, and drain the fuel into a suitable ccntainer. jemave the fioat bow! (@ Remove the screw [A] and take out the float (B].‘@Bend the tang [A] on the float arm very slightly to change the float height. Increasing the float height lowers the fuel level and decreasing the float height raises the Tuel level. Float Height Standaré: ‘DersON: «9 + 2mm perso: 18+ 2mm NOTE (00 not push the needle rod (A) in during the float hemht measure ‘ment (8) ‘@ Assemble the carburetor, and recheck the fuel level tif the fuel level eannot be adjusted by this method, the float or the float valve [CT is damaged. Fuel System Cleanliness Inspection NS) Gasoline fs extremely Nammable and van be wxplvoive under vertain conditions. Turn the fantion switch OFF. Do not smoke. Make sure the area is wellventilated and free from any source of flame or sparks; this Includes any appliance witha pllt light. ‘@Remove the fuel tank (sea Fuel Tank Removal) @ Connect a suitable hose [A] to the fitting at the bottom of each arburetor float bowl. ‘@Fun the lower ends of the hoses into a suitable container. (@Tuin out ezch drain plug [B] a fow turns and drain the Foat bow's. ‘Special Toot ~ Carburetor Drain Plug Wrench, Hex 3: 57901-1269 Check to see if water or dirt comes out, Tighten the drain plugs. tlt any water or dirt appears during the above inspection, clean the fue! system (see Carburetor Cleaning and Fuel Tank Cleaning). Carburetor Removal | Gasoline is extremely lammabie and canbe explosive under certain cconcltions. Turn the ignition swilch OFF. Do not smoke. Make sure the area is well-ventilated and tree trom any source of flame or “sparks; this Inckides any appliance witha plot light. FUEL SYSTEM 2-152-16 FUEL SYSTEM ‘Remove: Seats (see Frame chapte) Fuel Tank (see Fue! Tank Removal) Ar Cleaner Housing (see Ai Cleaner Housing Removal) Choke Cable Fuel Hose ‘@Looten te carburetor clamps [A], ond remove the carburtors Remove the throttle cables [8]. {Stuff piocos oF intro, clean cloth into the carburetor holds to keep in out ofthe engine. Carburetor Installation @Route the cables, hamess, and hoses corectly (see General Informa- tion chapter) @Tighton the clamps for the carburetor holders at the position in the ‘© Check fue! leakage from the carburetors, AYES Fuel spied from the carburetors is hazardous. ‘@ Adjust the following items if necessary. Idle Speed Carburetor Synchronization Throttle Cables Choke Cable Carburetor Disassembly/Assembly SGN Gasoline is extremely lammable and can be explosive uncer certain conditions. Turn the ignition switch OFF. Do nol smoke. Make sure the area is well-ventilated and free from any souree of tlame or ‘sparks this includes any appliance with a pict light {#70 remove the jet nasdle for the ZX780N, remove the plug [A]. (@For the US and Swiss models, remove the pilot serew plug as follows: ‘OPunch @ hole in the plug and pry there with an aw! or other suitable tol ‘@Turn inthe pilot serow and count the number of turns Until seats fully but not tightly, and then remove the screw. Use this number of turns. to set the screw to its original position during assembly. ‘@Atter installing the upper chamber cover, check that the vacuum piston sfides up and down smoothly without binding in the carburetor bore. ‘CAUTION During carburetor disassembly, be careful not to damage the diaphragm, Never use a sharp edge ta remove the diaphragm. ZX75OPFUEL SYSTEM 2-17 ‘eTurn in the pilot serew [A] fully but net tighty, and then back it out the same number of turns counted during disassembly. (OA carburetor has different “tuins out of the pilot screw for esch individual unit. When setting the pilot screw, use the “tums out” determined during disassembly. Use the specifications in this manual coll ifthe exiginal number is unknown. ‘@For the US and Swiss models instal the pilot screw plug as follows: Olnstall 2 new plug [B] in the pilot screw hole, and apply © small amount of a bonding agent [C] to the circumference of the plug to fix the plug. ‘CAUTION Do nok apply too much bonding agent to the plug or the pilot screw: itself may be tixed. x ‘e5sip the needle through the hole in the center of the vacuum piston, ‘and put the spring seat (AJ on the top of the needle. Tum the seat so that it dees not block the hole [3] atthe bottom of the vacuum piston, Carburetor Separation/Assembly ‘@ Read the WARNING in Carburetor Disassembiy/ Assembly. ‘@ The center lines of the carburetor bores must be parallel both horizon- tally and vertvally. Il they aie not, loosen the mounting eorowe and ‘lian the carburetors on 2 flat surface, Retighten the mounting screws. ‘@’Aftor assombling the choke mechanism, check to see that the starter plunger lever slides right to left smoothiy without abnormal friction. ree ‘CAUTION Fuel mixture rouble could result the starter plunger lever does not | seat property in its rest position after the choke lever is returned. ‘© Visually synchronize the throttle (butterfly) valves. ‘OCheck to see that all trate valves open and close smoothly without binding when tuming the pulley. (Visually check the clearance [A] between the throttle valve and the carburetor bore in each carburetor. “If there is difference between any two carburetors, tum the balance ‘adjusting screw(s) [B] to obtain the same clearance. Carburetor Cleaning AGN Clean the carburetors in a well-ventilated area, and take care that there Is no sparks or flame anywhere near the working area; this Includes any appllance with a pllot light. Because of the danger of highly flammable liquids, do not use gasoline or low flashpoint solvents to clean the carburetors.2.18 FUEL SYSTEM ‘CAUTION ‘Do not use compressed alr on an assembled carburetor, or the floats may be crushed by the pressure, and the vacuum piston dlaphragms may be damaged. Remove aa many rubber or plastic parts trom the carburetor as, possible before cleaning the carburetor with a cleaning solution. ‘Tha wil prevent damage to or deterioration of the parts. ‘The carburetor body has plastic parts that cannot be removed. Do not use a strong carburetor cleaning solution which could attack these parts; Instead, use a mild high flash-point cleaning solution safe for plastic parts. Do not use wire or any other hard instrument to clean carburetor parts, especially ets, as they may be damaged. Disassemble the carburetor. immerse all the metal parts in a carburetor cleaning solution (@Rinse the parts in water. (@When the parts are clean, dry them with compressed ai. ‘@Biow through the air and fuel passages with compressed ai (@Assemble the carburetor. Carburetor Inspection Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area Is well-ventilated and tree trom any source of flame or sparks; this includes any appilance witha pilot light. ‘@Remove the carburetors. Before disassembling the carburetors, check the fuel level (see Fuel Level Inspection). If the fuel level is incorrect, inspact the rast of the carburetor bafore correcting it ‘@ Move the starter plunger lever to the left and release it to chéck that the starter plungers move smoothly and return by spring tension. >If the starer plungers do not work properly, replace the carburetors. ‘@Turn the throttle cable pulley to check that the throttle butterfly valves [A] move smoothly and return by spring tension. elf the throttle valves do not mave smoothly, replace the carburetors. Disassemble the carburetors, lean the carburetors, {@Cheok that the O-rings on the float bowl and pilot screw and the diaphragm on the vacuum piston are in good condition. “elf any of the O-rings or diaphragms are not in good condition, replace them ‘@Check the plastic tip [A] of the float valve needle [B]. It should be ‘smooth, without any grooves, scratches, or tears, “elf the plastic tip is damaged [C], replace the needle. ‘@Push the rod [D] in the other end of the float valve needle and then release it. elf the rod does not spring out, replace the needle.